T9623-AC-MMC-010_0_0_PRELIMINARY.pdf

T9623-AC-MMC-010

091 O-LP-302-7900

PRELIMINARY

TECHNICAL MANUAL

FOR

ACCOMMODATION LADDER

FIXED-THREAD

MODEL: AAL-2.0-41.3-X-P

TAO-187 CLASS FLEET OILERS

, RAMPMASTER, INC.

CONTRACT NO.: NDDD24-83-C-2012

''. DISTRIBUTION STATEMENT E: DISTRIBUTION Al1THORIZED io DOO COMPONENTS ONLY; cRmCAL TECHNOLOGY; . · .. !: DATE OF PUBLICATION. OTHER REQUESTS SHALL BE REFERRED TO THE NAVAL SEA

'{ SYSTEMS COMMAND (SEA-4982).

1WARNING: THIS DOCUMENT CONTAINS TECHNICAL DATA WHOSE EXPORT IS RESTRICTED BY THE ARMS EXPORT CONTROL '· -ACT (TITLE 22, U.S.C, SEC. 27!11 ET. SEQ.) OR EXECUTIVE ORDER 12470. VIOLATIONS OF THESE EXPORT LAWS

, : . ARE SUBJECT TO SEVERE CRIMINAL PENAL TIES

' '' DESTRUCTION NOTICE: DESTROY BY ANY METHOD THAT WILL PREVENT DISCLOSURE OF CONTENTS OR RECONSTRUC-

. 'TION OF THE1DOCUIIENT. .

PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND

FOR OFFICIAL-USE,QNL Y NO DATE

LIST Of tJ·fECllVE

•~!Ill LATlSl C><ANC[O ••cu O[SHIOY ~u•I P<S[D[D ,,.c;[S

Non.: T~u pDnJOTI or I.hr ..... affrnrd br "'" c.ha.nrn u irid.o,aud by I ..-Tio(.., hnr Ul llu D\.11.n W'IL""J'i'N of U,r p&(T. 0-,LP'I~ ID ill..01nuoru an 1nd1r1ud br ...,..;&lu.n: poiaU"' hLC,,da. O:..n1C1 IC -VV\l c!i•JT"Ll'N an indll(UU! br --~~ .re.a..

C.tn ol iLW• for ori1,;r,ol .-,d d,anll<'(! ?09"' art

Ori9inal •• 0 ••

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS CONSISTING OF THE FOLLOWING:

Pq, Ne.

'IITJ.E

A

RECORD PAGE

APR

VALIDATION

i - xiv 1-1 - 1-15 2-1 2-3 3-1 3-2 4-1 4-20 5-1 5-4 6-1 6-2 7-1 8-1 8-15 9-1 9-16

INDEX

USER COMMENTS

J..

• °'""II< No.

o·

P09r No.

A

• Dl•npe No.

Pq Ne.

• Oun;c.

Ne.

CHANGE DATE

( NUMBER ENTERED

1'9623-AC-MMC-010

RECORD OF CHANGES

TITLE OR BRIEF

DESCRIPTION

ENTE~EDBY

TECHNICJ..L MANUAL VALIDJ..TION CERTIFICATE

NAVS[A ,,s:r~ 14-821

. lECHNICAL MAl<UAL lllLE

ACCOMODATION LADDER, FIX~ TREAD MODEL AAL-2.0-41.3-X-P

~N_•_vs~E-A-:-:TE~C~H-N~•~C-"L.,,...M_"_N_u_"_L_N_u_M_s_e_R ______________________ I._DA_T_e _______ _

CONlRACl/TMCR NO.

N00024-83-C-2012

I-VALIDATION

II-EXCEPTIONS

Except as stated in II. the technical manual identified above ha=, been satisfactorily validated in accordance with all requirements of the applicable TMCR and the approved Validation Plan. The technical manual is hereby certified 10 be accurate and complete, and the information, instructions, text, and illustrations conform in all respects to the applicable general and detailed specifications.

EXCEPTIONS AUTHORIZED BY

SIGNl.lURE OF PUBLICAllONS OUALllY ASSURANCE OFFICER DATE .__

T9623-AC•MMC-010

TABLE OF CONTENTS

Chapter Title Page No.

List of Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

List of Tables . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . vi

1 General

1-1

1-2

1-3

1-5

1-6

1-7

1-8

Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Introduction .................... 1-1

Model covered ................... 1-1

Equipment Description ••••••••••• 1-1

Equipment Supplied .••••••••••••• 1-1

Purpose arid Function •••.•••••••• 1-9

Special Tools And Equipment .•••• 1-10

Recommended list of Spare Parts. 1-14

Operation .- .................................... 2-1

2-1

2-16

Operating Instructions •.•••••••• 2-1

Ladder Stowage •••• -•••••••••••••• 2-2

Functional Description ..................... •- .. 3-1

3-1

3-3

3-13

3-14

Functional Description •••••.•••• 3-1

Sub-AsseillPlies •••.•••••••••••••• 3-1

Asse~ly ~........ .. . . . . . . . . . . . . . . 3-1

Lifting Winch Assembly ••••••••• -. 3-2

Scheduled.Maintenance . . . . . . . . . . . . . . . . . . ~ . . . . . . 4-1

4-1

4-4

---~---=--------4--1:0~

Scheduled Maintenance ••••••••••• 4-1

General Notes ••.•••••••••••••.•. 4-1

Preventd-ve Maintenance Inspection . . . . . . . . . . . . . . . . . . . . . . · 4-3 . ..

i

4-11

4-18

4-26

4-28

4-30

4-36

4-38

4-41

4-43

4-46

4-51

4-57

4-62

4-70

4-75

4-77

4-77-1

4-77-2

4-77-3

4-77-4

"i"i,i;23·AC-MMC·010

TABLE OF CONTENTS (CONTINUED)

Handrail Attachments •.••••.••.•• 4-3

Ladder Safety Lines ••.••••••.••• 4-4

Handrail Safety Chains ••••••.••• 4-5

Stowage Links, Tie-down Links and Deck Stanchions ••••••••••••• 4-5

Boat Fender • • • • • • • • • • • • • • • • • • • • 0

Padeyes

Rollers

• • • • • • 0 • • • • • • • • • • • • • • • • • •

Links 0 0 0 • 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 e • 0 • • f O 0

4-5

4-6

4-6

4-7

Upper Platform Hinges .•••••••••• 4-7

Upper Platform Assembly

Lower Platform Assembly

4-8

4-8

Pendants and Bridles •••••••.•••• 4-9

Wire Rope Pendants and Slings ••• 4-10

Spreader Bar

Lubrication

. . . . . . . . . . . . . . . . . . . . 4-11

4-11

Inspection Types •••.•••••••••••• 4-13

Motor ..... •..................... 4-13

Gear Coupling ..................• 4-14

Gear· Reducer

Pillow Block Bearing 4-15

4-18

5 Troubleshooting ............................... 5-1

5-1

5-2

Troubleshooting ..•.•••••••••.••• 5-1

General Troubleshooting - Thern 4D3 Power Winch ••...•.•••• 5-1 ..

ii r , T9623-AC-MMC-010

TABLE OF CONTENTS (CONTINUED)

Corrective Maintenance •....................... 6-1

6-1

6-3

6-6

6-8

6-10

Parts List

Corrective Maintenance •••••••••• 6-1

Lifting Winch ..•..•.........•... 6-1

Winch Motor Brake ••.•••..•.••.•. 6-1

Winch Motor Gear Reducer .••.••.• 6-1

Motor/Reducer Coupling . . . . . . . . . . 6-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Installation and Testing ...................... 8-1

8-1

8-4

8-4-a

8-4-b

8-4-c

8-4-d

8-4-e

8-4-e

8-4-f

8-4-g

8-4-h

8-4-j

8-4-k

Installation and Testing .••.•••. 8-1

Installation • • • • • • • • • • • • • • • • • • • 0 8-1

Deck Stanchions . . . . . . . . . . . . . . -. . 8-1

Stowage Support Stanchion •.•.•.• 8-1

Tilting and Lifting Winches •..•.. 8-1

Lifting Winch Lead Bloc~ Padeye. 8-4

Tie-down Link (With Stop) •.••... 8-4

Tie~down Links (Without Stops) •• 8-4

Hinged Jib . . . . . . . ... . . . . . . . . . . . . . 8-6

Stowage Link Lugs •••••.••.••.•••. 8-6

Upper Platform Lugs · •••••••••.•.• 8-6

Upper Platform

Lower Platform

8-6

8-6

8-4-m Stowage Links •.•..•..••.••..•.•• 8-11

8-4-n Lifting Sling Assembly •..•..•.•• 8-11

9.:.4-oc==-- =-Til ting~winch Cable- • •.;. . . . . • • . • 8-11 iii

1'9623-AC-MMC-010

_TABLE OF CONTENTS (CONTINUED)

8-4-p

8-4-p

8-4-p-l

8-4-q

8-4-r

8-39

8-39-a

8-39-b

8-39-c

8-39-d

Appendix A

10 Index

Chain Pendant/Wire Rope Pendant Combinations •••••••••••. 8-11

Wire Rope Pendants •••••••••••••• 8-11

Lifting Sling Spreader Bar •••••• 8-11-

Stanchions, Safety Chains and Handrails ••••••••••••••••••••••• · 8-11

Push Button Control Station ••••• 8-13

Testing . . . . . . . . . . . . . . . . .. . . . . . . . . 8-14

Test Loads . . . .. . . . . . . . . . . . . . . . . . . 8-14

Duration of Test Loading •••••••• 8-14

Relocation of Tread Loads ••••••• 8-15

Operational Tests -• . • • • • • • • • • • • . . 8-15

Reference Material f.or Principal Assembli~s ........... Cl .. • .. • .. • • • • ... • 9-1 iv l

T9623-A~MC-010

LIST OF ILLUSTRATIONS

Figure Page

1 General Arrangement - Accommodation Ladder System . a............. . . . . . . . . . . . . . . . . 1-2

2 Lubrication Diagram ......... a... . • . . • . . • . . . 4-20

3· Accommodation Ladder - Plan and Profile ... 8-2

4 Tilting Winch Mounting Details ..•....•..•. 8-3

5 Stowage and Tie-down Link Attachment •..... 8-5

6 Upper Platform Attachment Details ••.•....• 8-7

7 Ladder Connection Pin and Keeper Plate .••• 8-10

8 Hinged Jib Arrangement .••••..•••.......... 8-12

V

LIST OF TABLES

Table Page

1 Vessel Freeboard vs. Operating Angle •.••• 1-9

2 Scheduled Maintenance Operations ••...••... 4-2

3 Lubrication Chart . • . • • • • • • . • • • • • . . . • . . • . . . 4-12

4 Chain Pendant/Wire Rope Pendant Coml:)inations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

5 Vessel Freeboard vs. Operating Angle ••.•.. 8-9 vi

G A~ WA 'I W l h c. h P1-&T~ Ir f e1r1

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1 -

T9623-AC-MMC-010

SAFETY SUMMARY

The following WARNING, CAUTION, and in various chapters of this manual.

on these Safety Summary Pages as an emphasis.

NOTE paragraphs appear They are repeated here example and for

WARNING paragraphs must be observed to prevent serious injury or death.

CAUTION paragraphs must be observed to prevent damage or destruction of the equipment or loss of operating effectiveness._

NOTE paragraphs must be observed for essential and effective operating procedures and conditions, and as a statement to be highlighted.

It is the responsibility and duty of all personnel involved in the operation and maintenance of this equipment to fully understand the WARNING, CAUTION, and NOTE procedures by which hazards are to be reduced or eliminated. Personnel must become thoroughly familiar with all aspects of safety and equipment prior to operation or maintenance of the equipment. ·

The lowe_r platform is adjustable to suit ladder operating angles of 0, 15, 20, 30, 35, 40, 45, 50 and 55 degrees. For the proper combination of chain and wire rope pendants for the operating angle desired, see Table 4.

vii

I

T9623-AC-MMC-Ot0

SAFETY SUMMARY

(CONTINUED)

B For Wire Rope Pendant/Chain Pendant combinations for required service positio~s, see Table 4.

B A tag line is provided to retrieve the.hoisting rope.

CAUTION

Mechanical means snould never be used to force-fit the clevis pins.

CAUTION

No attempt should be made.to repair damaged screw pin threads. All worn parts should be replaced.

CAUTION

Do not attempt to repair a d·amaged Boat Fender.

viii r

1'9623-AC-MMC-010

SAFETY SUMMARY

(CONTINUED)

CAUTION

The use of the ladder without the Boat Fender could result in damage to the lower ~latform and/or ladder assembly.

CAUTION

Never reuse cotter pins. Always replace with new cotter pins of proper diameter and length.

I CAUTION I

Never paint the Chain Pendants.

I· CAUTION

Never use mer~ than one (1) missing link per Pendant.

CAUTION

Never paint Wire Rope Pendants or Slings.

ix

SAFETY SUMMARY

(CONTINUED)

CAUTION

Never use a bent Spreader Bar.

No lubrication is needed before start up.

The bearings have been lubricated at the factory.

CAUTION

Keep grease clean. Lubricate motor at a stand still. Do not mix petroleum grease and silicone grease in motor bearings.

No lubrication is needed before start up.

The couplings have been lubricated at the factory.

CAUTION

Do not overfill the coupling.

X

SAFETY SUMMARY

(CONTINUED)

For applications that involve severe ambient temperature extremes or seasonal requirements, use Mobil SHC 626. .

CAUTION

Do not overfill the Gear Reducer.

WARNING

This unit may not be lubricated from the factory.

Before start. up check fluid level and fill as necessary.

To prevent loss of oil during shipment, the Gear Reducer unit is shipped with~ brass·pin in the· vent hole in the fi~ler .and vent plug. Be sure that this pin .is removed and discarded prior to initial operation of the unit.

xi

T96l!3-.&J:-IAMC-010

SAFETY SUMMARY

(CONTINUED)

WARNING

Disconnect the unit from the primary power supply (preferably by removing the circuit breaker) before attempting any inspection or repai_r.

Installation instructions are given for the STARBOARD ladder only. The port ladder is to be installed in a similar fashion.

Care is ·to be taken when installing the winches to avoid interferences with structure, deck equipment, etc.

CAUTION

The fleet angle between the centerline of the drum on· the Tilting and Lifting Winches and their respective Lead Blocks is not to exceed 1 1/2 degrees.

xii

T9623-AC-MMC-010

SAFETY SUMMARY

(CONTINUED)

The lower platform provides adjustment to suit ladder ·operating angles of 0, 15, 20, 35, 40, 45, 50 and 55 degrees. The proper combinations of Wire Rope Pendants and Chain Pendants for the service positions indicated are shown in Table 4.

The operating angle of the,ladder may be deter mined from the approximate freeboard as ·shown in Table 5. The maximum allowable operating angle is 55 degrees from the horizontal. (This angle corresponds to a fre·eboard of approximately 34 feet.)

CAUTION

Clevis pins should be free of cracks and bends and should slide freely through the sockets and stanchions without the use of force. Under no circumstances should mechanical means be used to force-fit the clevis pins.

The maximum voltage in the control circuit is not to exceed 115 VAC.

xiii

SAFETY SUMMARY

(CONTINUED)

I WARNING

Under no circumstances are personnel to "ride" the ladder while it is being raised or lowered for testing or use. Personnel are to remain well clear of the ladder during operation.

CAUTION

Be certain that the lifting sling is removed from the ladder before the test loads are applied. All test loads must be borne by the bridle-pendant assembly only. Under no circum stances is the Lifting Winch to be allowed to carry the test loads.

For Operating Instructions see Chapter 2.

xiv

---; 1-

T9623-AC-MMC-010

A complete list of all safety precautions may be found in the Safety·summary at the conclusion of the Front Matter.

1-1 INTRODUCTION

This manual covers the installation, testing,· operation, inspection, maintenance, troubleshooting and repair of the Rampmaster, Inc. 41'-4" Fixed Tread Accommodation Ladder Model AAL-2.0-41.3-X-P. Also included in this manual is a parts list and a list of vendor furnished material. ·

1-2 MODEL COVERED. This manual covers the Rampmaster Accommodation Ladder Model AAL-2.0-41.3-X-P and all associated equipment for its proper operation.

1-3 EQUIPMENT DESCRIPTION. (See Fig. 1) The Rampmaster Accommodation Ladder Model AAL- 2.0-41.3-X-P consists of a fabricated aluminum ladder section, upper and lower·platforms, remov able safety rails and chains, chain and wire rope pendants, a lifting bridle assembly, tilting and· lifting winches and a hinged jib. The tilting winch is hand-operated and has a·one-ton capacity, with a 2 l/2"·dia. drum for 5/16" wire rope. The lifting winch is electrical, with a 1500 lb. load rating.

The drum diameter is 6.62" with a capacity of 160' of 3/8" wire rope. Line speed is 20 £pm. The motor is 1 1/2 HP," NEMA 145T, 460 volts, with 120 volt heaters in windings and brake. For additional infor mation, locked rotor and breakdown torques, etc. see Appendix A. The tilting winch lowers the ladder· from its stowed position to its horizontal position.

From this point, the lifting winch will lower the ladder to the operating position where the ladder will be supported by the hinged jib. The lifting winch is also used to raise the ladder to a horizon tal attitude after use. A limit switch, incorporated into the upper end of the ladder, shuts down the lifting winch when.the ladder reaches the horizon~al attitude. This action prevents damage to the ladder and jib, and possible injury to personnel. A remote pushbutton station controls the lifting winch.

(Information on the lifting winch, the limit switch and-pushbutton·statiori-can be found in Appendix- A.)

When not in use, the ladder is stowed along the gunwale and is secured to stanchions on the deck.

1-1

T9623-AC-MM C-010

FR•? :-~,-~ FR•;~IN rf'Clt

__..,- - LIFTING

~------- \ WINCH

.a!ll

STBO. SIOE SHOWN

,.R~ {SHI?

-:2115Rm!U

STATION ON

c_7 j ct= r~ PIVOT PT

I FRJ4B FRI•?

~="'· -=~z•{.==j_ • i - -------F =~-

FR1•S FRI"

;,1'::@ '

11· 'I 22 · . ___,TILTING @~P)

WINCH @(S)

- . - MN K

WL

FIG. l

1-2 r·, T9623-AC-MMC-010

The lower platform is adjustable to suit ladder· operating angles of 0, 15,· 20, 30, 35, 40, 45, 50 and 55 degrees. For the proper combination of chain and wire rope pendants for the operating angle desired, see Table 4.

1-5 EQUIPMENT SUPPLIED. The following is a list of ·material and equipment furnished by Rampmaster; Inc.

Material shown is for two (2) accommodation ladders.

(See Fig. 1).

VENDOR FURNISHED MATERIAL

ITEM QTY. DESCRIPTION RAMPMASTER PART NO.

1 2 Ladder Assembly 1083053-ALOl-lA

2 36 ·Handrail Stanchion 1083053-ALO4-4A

3 4 Handrail 1083053-ALO4..,:4B

4 4 Rope Rail (Upper Course) 1083053-ALO4-4G

5 Not Us~d

6 2 Boat Fender 1083053-ALO3-3H

7 2 Dock Roller 1.083053-ALO3-3B

Note: Quantities shown are for two (2) ladders

1-3

VENDOR FURNISHED MATERIAL

ITEM QTY DESCRIPTION RAMPMASTER PART NO.

8 1 Upper Platform (Stbd.) 1083053-UPOl-(S)

9 1 Upper Platform (Port) 1083053-UPOl-(P)

10 4 Handrail Stanchion "A" 1083053-UPOl-A

11 2 Handrail Stanchion "B" 1083053-UPOl-B

12 4 Handrail Stanchion "C" 1083053-UPOl-C

13. 4 chain Rail Assembly 1083053-UPOS-SJ

14 4 Chain Rail Assembly 1083053-UPOS-SJ

15 4 Chain Rail Assembly 1083053-UPOS-SJ

16 4 Chain Rail Assembly 1083053-UPOS-SJ

17 ·2 Spreader Bar 1083053-LGOl-lC

18 1 Lower Platform (Stbd.) 1083053-LPOl-lA

19 6 Handrail Stanchion 1083053-LPOl-lD

20 4 Chain Rail Assembly 1083053-LPOl-lJ

21 2 Jib· 1083053-HPOl-lA /

Note: Quantities shown are for two ( 2) ·ladders

1-4

ITEM QTY DESCRIPTION RAMPMASTER PART NO.

22 6 Snatch Block 1083053-GAO2-22

23 2 Padeye 1083053-LGOl-lD·

24 22 Anchor Shackle, 3/4" 1083053-GAO2-24

25 1 Tilting Winch (Port) 1083053-GAO2-25

26 1 Tilting Winch (Stbd.) 1083053-GAO2-26

27 2 Winch Foundation 1083053-STO2-1A

28 2 Padeye 1083053-STO2-1C

29 2 Stowage Support 1083053-STOl-lA

30 6 Tie-down Link 1083053-STOl-lE

31 20 Stowage Link Lug 1083053-STOl-lD

32 4 Upper Platform Lug 1083053-STOl-lD

33 2 Wire Rope Pendant (11') 1083053-:LGOl-lA

34 2 Wire Rope Pendant (17') 1083053'--LGOl-lA

35 2

Wire Rope Pendant (2~') 1083053-LGOl-lB

Note: Quantities shown are for two (2) Ladders

1-5

ITEM QTY. DESCRIPTION RAMPMASTER PART NO.

36 2 Chain Pendant (16') 1083053-GAO2-36

37 4 Bridle Chain (7') 1083053-GAO2-37

38 350' Wire Rope, 3/8"6x37 IWRC 1083053-GAO2-38

39 2 Lifting Sling 1083053-LGOl-lB

40 1 Lower Platform (Port) 1083053-LPOl-lA

41 10 Stowage Link 1083053-STOl-lC

42 10 Hex Bolt, 1"8UNC-2A S.S. 1083053-GAO2-42

Pin, l" D. x 28 3/8" S.S. 1083053-GAO4-43

Hex. Nut, 1" 8UNC-2B S.S. 1083053-GAO4-44

Cotter Pin - 0.109" D. x 2".long S.S. 1083053-GAO4-45

Washer, 1'' flat, S.S.

Lockwasher, 1", S.S.

Hex, Bolt -

3/8"16UNC-2A S.S.

1083053-GAO4-46

1083053-GAO4-47

1083053-GAO4-48

1-6

1'9623-AC-MMC-010

VENDOR FURNISHED MATERIAL

ITEM QTY.

49 8 so -8

51 50'

52 30

DESCRIPTION

Hex. Nut -

3/8"-16UNC-2B S.S.

Lockwasher, 3/8", S.S.

Wire Rope - 5/16" 6 x 19 Preformed

Clevis Pin, 3/4"

RAMPMASTER PART NO.

1083053-GAO4-49

1083053-GAO4-50

10E•3053-GAO4-51

1083053-GA04-52

53 2 Tie-down Link (with stop) 1083053-STOl-lF

54 1-- Lifting Winch ( Stbd.) 1083053-GAO4-54

55 1 Lifting Winch (Port) 1083053-GAO4-55

56 2 Pushbutton Station 1083053-GAO4-56

57 6 Anchor Shackle, 3/8" 1083053-GAO4-57

58 2 Tag Line, 1/2" D. NY:lon 1083053-STO2-1D

59 .16 Chain Rai-1 Assembly 1083053-UPOS-SJ

1-7

~3-Ac-MMC-f'l10

VENDOR FURNISHED MATERIAL

ITEM 'QTY. DESCRIPTION

60 2 Limit Switch Bracket

61 1 Limit switch (Port) - ------- --(-A-1-len-Brad-ley) - -----

1 Limit Switch (Stbd.) - (Allen-Bradley)

2 Motor Controller - (Federal Pacific)

Electric Motor - (Baldor)

Electric Motor Brake - (Stearn)

RAMPMASTER PART NO.

1083053-UPO2-2J

802-MC-A1Y8

See-Appendix- A

802-MC-A2Y8

See Appendix A

See Appendix A

See Appendix A

See Appendix A

Note: Quantities shown are for two (2) Ladders

Rampmaster Part No. Code:

For Rampmaster-manufactured parts:

1083053,' . contract No.

LG0l Drawing-No.

For parts manufactured :ey others:

10830-53 Contract No.

GA02

Drawing No.

lC Detail No •

Mark No. in Parts List

Note: Part Numbers referred to Appendix A are manufacturer's part numbers.

1-8 j

T9623-AC..P.4MC-010

1-6 PURPOSE AND FUNCTION. The Rampmaster Model AAL-2.0- 41.3-X-P. Accommodation Ladder is designed to be a permanently attached, easily operated, stowable access ladder for shipboard use. When not in use, the ladder stows out of the way along the gunwale on

·either side of the ship. When in use, the operating angle of the ladder may be adjusted to suit various freeboards as shown in Table 1. Shell.and deck rollers and a tubular boat fender are fitted at the lower end of the ladder to protect the ladder from damage in a seaway.

VESSEL FREEBOARD VERSUS OPERATING ANGLE

APPROX. FREEBOARD MAX·. OPERATING ANGLE

13' 15 degrees

16' 20 degrees

26' 35 degrees

31' 45 degrees

36' 55 degrees

Table 1

The ladder is stowed and unstowed by means of a Tilting Winch. This winch is. hand operated, and is used to tilt the ladder inboard for stowing or to swing it outboard into the horizontal position in preparation for lowering it•alongside at the chosen operating angle. In the horizontal position, the ladder is fitted with stanchions, handrails and safety chains; the Chain and Wire Rope Pendants are fitted; the Lower Platform is adjusted to suit the

,_g

1'9623-Ac-MMC-010 operating angle; and the lifting bridle assembly and the line from the Lifting Winch are attached.

The Lifting Winch is electrically operated and is used to move the ladder into and out of the operating position. The Chain and Wire Rope Pendants are attached to a Hinged Jib located on the deck, and support the weight of the ladder when it is in use.

When not being used to move.or temporarily support the ladder, the lines from the Tilting and Lifting Winches are removed from the ladder and stored on their respective winch drums.

1-7 SPECIAL·TOOLS AND EQUIPMENT. No special tools or equipment are needed for installation or operation.of the Rampmaster Accommodation Ladder.

LIST OF

RECOMMENDED SPARE PARTS

There are no regula~ory body requirements for spare parts for Accommodation-Ladder Systems •. However, Rampmaster, Inc. recommends the following_spares:

DESCRIPTION QTY. RAMPMASTER PART NO.

Boat Fender 1_ 1083053-AL03-3H

Stanchion 1 1083053-LP0l-lD

Snatch Block 1 1083053-GA0Z-22

Anchor Shackle 2 1083053-GA02-24

Clevis Pin 2 1083053-LP0l-11

Safety Pin 2 1083053-LP0l-12

1-10

,i- -

1'9823-AC-MMC-010

LIST OF RECOMMENDED SPARE PARTS (CONT'D)

DESCRIPTION QTY. RAMPMASTER PART NO.

1/4" Chain 6 L.F. 1083053-LP0l-13

Limit Switch (Port) 1 1083053-GA04-59(P)

Limit Switch (Stbd.) 1 1083053-GAO4-59(S)

Limit Switch Lever 1 Allen-Bradley

802MC - W2B

Friction Disc 1 Stearns 8-004-504-00

Tilting Winch Beebe Bros.

Large Side Frame 1 MRP 73-A

Tilting Winch Beebe Bros.

Small Side Frame 1 MRP 75-A

1-9 WEIGHTS AND CENTER OF GRAVITY INFORMATION.·

Weights and center of gravity diagrams are given on the following pages for the following principal assemblies: Ladder, Lower Platform, Upper Platform, Lifting ~inch, Tilting Winch and the Hinged Jib.

The total weight of the principal assemblies is 2674 pounds.

1-11

41 ~ 4 11

'20

- 1

11 '21 1-a11

= ~ =i----------:-1-,---------____,..;][

=-i!L .--------'-----+· ------------, Fl -:4= E: LEVATIOi,..J

L.A-DDE:R

WE:161-tT:. 1460 Ll:15 .

' .31-1 o'l-i' ,

- '2 1

- 4 11 , 11-G:l!i' I

~ . +--. ---1----=-~-~-1-

PLAN

E:LEVATIOt-J

LOWE:12 PL.A..TF-012.t,.....,1 WE 161-lT ::= 11 Co LF.i5.

1-12

4'- 'Z. s.;,e;'

I II

'2- ~,3/4-

II

-10'1/e

I \ =~

I,('\

' l,f =~

I ,..c

I

PL.Ai-J

- !O ~ I I

"" I '. -~ rrl I

" I

I ...

E·LeVA1I Ot-J

UPPE:-12. PLA.TF-012M

WE:IC::il--lT = 3'2.~ Ll?5 •

1-13

I I

I I

T9623-AC-MMC-010

- '"" 4' s,''=/i II

2 1-4~/~11

I 0 -

- :1 I -

PL.A.t,.J

- r;-

I --, ELE:VA"TION

LIF-"Tli-.J6. Wli-.JC.H Wc.16HT= SOO LP.;,'=>, E: L E VA "T I O t,.J

TILTII-JC:i WINCH WE16HT = '2.4 Le>'5.

1-14

~ _j n i--d)

'~-, I 11

- _J - -, -~ I t--J '=tcO .JI I?

WE.IC:11--IT = '2.:i4 LP.i5.

1-15

2-1 OPERATING INSTRUCTIONS

The following procedures are to be used to prepare the accommodation ladder for use. (See Figs. 3 and

4) :

a. The tilting winch is to be rigged and the winch cable secured to pad on ladder.

b. The pins that secure the ladder to its stowage supports are to be removed.

c. Using the Tilting Winch, the ladder i~ to be swung outboard, stopping in the horizontal position.

d. The following components are to be installed.

(See Figs. 2 and 5):

( 1) Upper Platform Stanch~ons and Sa·fety .Chains. ·

(2) Ladder Stanchions and Handrails.

(3) Lower Platform Stanchions and Safety Chains.

(4) Lower.Platform onto Accommodation Ladder.

e. The Hinged Jib and Lifting Sling are to be rigged and the Lifting Sling secured to the Lifting Pads on the ladder. (See Figs. 2 and

. 7) :

f. The following are to· be secured:

(1) Bridle Chains to pads on ladder and to Spreader Bar;

(2) Wire Rope Pendant and/or Chain Pendant to Spreader Bar;

2-1

(3) Chain Pendant/Wire Rope Pendant •Assembly to Jib.

For Wire Rope Pendant/Chain Pendant combinations for required service positions, ~ee Table 4.

g. The lifting winch is energized by a remote push button station located on the deck edge. The pushbutton station consists of one up and one down button connected to the winch -motor. The up button may be overridden by the limit switch located on the upper end of the ladder. This limit switch ensures that the ladder does not overrun the horizontal position by discontinuing contact between the push button station and the winch motor. The down button on the remote station overrides the limit switch to enable the ladder to be lowered again.

h. Using the Lifting Winch, the ladder is to be raised to relieve stress in the Tilting Winch cable and the Stowage Link Securing Pins. ·

i. The Tilting Winch cable is to be removed from the ladder and stored on the winch drum.

j. The Stowage Link Securing Pins are to be removed and the links swung inboard. (See Fig. 4)

k. The ladder is to be lowered to the desired service position, until the entire weight of the ladder assembly is supported by the bridle assembly and pendant(s).

(1) The Lifting Sling is to be removed and the winch cable stored on the winch drum.

2-16 LADDER STOWAGE. To stow the ladder, the operations in Paragraph 2-1, above, are to be reversed.

2-2

~ tag line is provided to retrieve the hoisting rope.

2-3

T9623-Ac-MMC-010

3-1 FUNCTIONAL DESCRIPTION

The Rampmaster Model AAL-2.0-41.3-X-P Accommodation Ladder is operated by hand and electric winches which tilt the ladder outboard from its stowed position along the gunwale of -the ship and lower it alongside to any of four (4) service positions.

3-3 SUB-ASSEMBLIES. The Accommodation Ladder consists of ten (10) major sub-assemblies, as follows:

a. Ladder Assembly - Rampmaster

b. Upper Platform - Rampmaster

c. Lower Platform - Rampmaster

d. Tilting Winch - Rampmaster (Beebe Bros.)

e. Lifting Winch, Motor, Reduction Gear, Coupling and Brake -Thern, Baldor, Winsinith, Dodge Powerlign ·.

and Stearn. (See Appendix Al

f. Pushbutton Control St~tion - Federal Pacific (See Appendix A)

g. Pendants, Bridles, Slings and Related Hardware - Rampmaster

h. Handrails, Stanchions and Safety Chains and Lines - Rampmaster

i. Hinged.Jib - Rampmaster

j. Miscellaneous Links, Lugs, etc. - Rampmaster

3'-13 ASSEMBLY. The Accommodation Ladder is to be assembled in accordance with Chapter~ - Installation and Testing.

3-1

3-14 LIFTING WINCH PARTICULARS; The lifting winch is a Thern Model #4D3 with a 1 1/2 H.P. motor. The winch capacity is 1500 lbs. with a hoisting speed of approximately 20 feet per minute. The winch motor i_s a Baldor dirty duty with marine duty brake. Its electrical requirements are 220 or 440 volts AC, 3 phase, 60 cycles. The motor has a NEMA 145T frame,a full load amperage of 2.·4 amps and a locked rotor amperage of 17 amps.

3-2 i

1"9623-AC-MMC-010

4-1 SCHEDULED MAINTENANCE

The accommodation ladder system is designed for minimum maintenance. However, certain preventive maintenance operations are necessary to ensure that all components are functioning properly and that portable sections properly mate to the ladder itself. ·

a. Scheduled maintenance operations are listed in Table 2, and should be thoroughly reviewed to familiarize the operator with the standard checks necessary to ensure that the ladder will operate as intended and will safely transport personnel on and off the vessel.

4-4 GENERAL NOTES

a. Clevis pins and shafts should be replaced when the minimwn diameter of the worn area is 80% or less of the original nominal diameter.

Example:

Clevis pin original nominal diameter is 0.375" (3/8") Minimum allowable diameter= 0.8 x 0.375

= 0.300" b, Rampmaster, Inc. should be notified of· any defects to welded sections of the accommodation ladder system. Repair should not be attempted without approval of Rampmaster, Inc., or its authorized representative.

c. Holes that are .intended to accept clevis pins or shafts should be repaired when the amount of elongation in any direction exceeds 20% of the nominal diameter of the hole. Rampmaster, Inc. should be consulted to determine the method of repair if the.hole is part of a welded structure.

Example:

Nominal diameter of a hole intended to receive•

4-1

REQIJRNCl' >

LADDER COMPONENTS INSPECTION NO. OF EVERY USE OR QUARTERLY SEHi -ANNUALLY ANNUALLY

TYPE LOCATIONS MONTHLY

1. HANDRAIL ATTACHMENTS

4111 A. LADDER 24 X

B. UPPER PLATFORM 7 X

c. LOWER PLATFORM 3 X

2. LADDER SAFETY ROPES 4~18 4 X

3. HANDRAIL SAFETY 4-26

CHAINS 10 X

4. STOWAGE, TIE-DOWN 4-28

i LINKS 15 X ~ c.>

' I

5. BOAT FENDER 4-30 1 X r; N

6. LIFTING & TILTING 4-36

!C

0 PADEYES 3 X 0 ...

7. SHELL & DOCK ROLLERS 4-38 2 X

8. STOWAGE LINKS & 4-4-1

UPPER PLATFORM HINGES 4-43 6 X

9 • UPPER PLATFORM ASSY. 4-46 1 X

10. LOWER PLATFORM ASSY. 4-51 1 X

11. PENDANTS & BRIDLES 4-57 3 X

12. WIREROPE PENDANTS & 4-62 X

SLINGS

13. SPREADER BAR 4-70. X

l*REFERS TO PARAGRAPHS IN SECTION 4 OF THIS MANUAL!

' TABLE \

a 3/8" diameter clevis pin is 0.4375" (7/16").

Maximum allowable elongation= 1.2 x 0.4375"

= 0.525"

4-10 PREVENTIVE MAINTENANCE INSPECTION

4-11 HANDRAIL ATTACHMENTS. Handrail attachment consists of placing the stanchion into a support socket and securing the stanchion within the socket by use of a clevis pin attached to the handrail by a lanyard and safety pin. '

a. The clevis pin should be inspected for cracks and bends. The pin should slide freely through the socket and handrail without the use of force.

Mechanical means should never be used to force-fit the clevis pins.

b. Replace all bent or cracked clevis pins immedi ately.

c •. Broken lanyards and safety pins should be replaced immediately to prevent the loss of the clevis pins.

d. Inspect all socket assemblies for out-of roundness that would prevent the smooth insertion of the handrails. Inspect the welds· securing the sockets to the ladder and platforms for cracks. Damaged sockets should be replaced.

e. The preceding checks should b~ made prior to ea~h ~use of the l_a_dder, _ and at all locations _on the ladder; upper platfo_rm, and -lower- platform. --

4-3

4-18 LADDER SAFETY LINES. The Ladder Safety Lines (upper and lower courses) are comprised of 2-1/4" circum ference polypropylene rope.

a. Thoroughly examine the outer surface of the rope for abrasions., cut or broken fibers, variations in the size and shape of the strands, and uni formity of the lay. Ropes should be replaced if examination of the outer surface reveals fibers and yarns worn more than halfway through.

b. Excessive chafing rail stanchions.

very carefully.

may occur in way of the hand These areas should be inspected

c. Hard twist the strands so as to open the rope to reveal the condition of the internal fibers.

Evidence of severed, melted or fused fibers is a danger sign indicating excessive internal bending, tension and wear. Repeat this test in several places. Yarns should be clean, bright and free of areas of discoloration or melting.

d. Acid or alkaline chemical damage is indicated by faded or discolored areas. Ropes having chemical damage should be replaced immediately.

e. The thimbles and· eye splices and the seizing at the ends of each handrail rope should be inspec ted for damage and discoloration as described above. A thimble that is more than 1/3 worn through should be replaced. Inspect the shackle and screw pin for signs of wear.

No attempt should be made to repair damaged screw pin threads. All worn parts should be replaced.

4-4

T9623~Ac-MMC-010

f. If all the foregoing tests are within the limits specified, the rope is suitable for use.

4-26 HANDRAIL SAFETY CHAINS

a. Handrail safety chains o_n the Upper and Lower Platforms should be inspecte~ for wear. Ensure that all swivel eye-bolt snaps operate freely and completely. Replace all worn chain and swivel eye-bolts immediately.

4-28 STOWAGE LINKS, TIE-DOWN LINKS AND DECK STANCHIONS

a. Inspect all stowage links, deck stanchions, tie-down links and clevis pins for wear.

Inspect clevis pin holes for elongation and cracking. Clevis pins should be straight and free of cracks. The pin should slide freely through the mating parts. Replace.all damaged links and lugs. Broken clevis pin lanyards and safety pins should be replaced to prevent loss of the clevis pins. (See GENERAL NOTES 4-4-a and 4-4-c).

4-30 BOAT FENDER

a. The tubular Boat Fender should be straight and free of kinks and excessive bends. .The fender must slide freely in its guide brackets.

b. Inspect the_locating-pin holes in the fender for elongation·and cracking that would weaken the tubing. Replace the Boat Fender. if any doubt of its structural integrity exists or if it is bent to such an extent that it cannot slide freely in its guiaes. (See GENERAL NOTES 4-4-a and 4-4-c).

4-5

Do not attempt to repair~ damaged Boat Fender.

c. Inspect the Boat Fender locating clevis pin to be sure that they are free of cracks and are straight. Replace any cracked or bent clevis pins. (See GENERAL NOTE 4-4-a). Replace any broken lanyards and safety pins to prevent loss of the clevis pins. ·

I CAUTION I

The use-of the ladder without the Boat Fender could resultin damage to the lower platform and/or ladder assembly.

4-36.PADEYES

a. Inspect the Tilting Winch line-attaching padeye, located about midway on the_ ladder stringer, and both lifting padeyes, located at the lower end of the ladder assembly for elongation and cracking in way of the sling and pendant attach ment holes. Replace all padeyes showing signs of ·elongation or cracking. (See GENERAL NOTE 4-4-c).

4-38 ROLLERS

a. Inspect the Shell Roller. It should rotate free ly without binding. Replace roller if the wheel is damaged or bent sufficiently to cause binding, or if there are cut. or missing sections on the · outer surface of the wheel.

4-6

™23-AC-MMC-010

b. Inspect the Dock Roller and bushings; The roller should rotate freely. Replace the bushings if they are cracked or have missing sections.

4-41 LINKS. The ladder assembly has six (6) pivot or tilting connections which allow it to tilt 90 degrees to and from the stowed_position.

a. Inspect all pivot assemblies for freedom of rotation. Do not lubricate. If binding occurs, inspect the alignment of all parts carefully to determine the cause. The ladder must pivot about these hinge points when moving to and from the stowed position.

4-43 UPPER PLATFORM HINGES

a. Inspect the Upper Platform-to-deck hinge assemblies. The platform should rotate freely about the deck connections.· Do not lubricate these pivot points. If binding occurs, inspect the alignment of all parts to·determine the cause.

Check the platform·axle and the ·axle support brackets for wear. Inspect the axle bearing holes for cracking and elongation·. Replace all damaged brackets. Inspect the platform axle for straightness. Wear in way of the support brackets should not exceed 0.010". Ensure that the ·axle keeper cotter pins are properly installed.

Never reuse cotter pins. Always replace with new cotter pins of proper diameter and length.

4-7

1'9623-AC-MMC-010

4-46 UPPER PLATFORM ASSEMBLY. Inspect the Upper Platform Assembly as follows:

a. Yoke Assembly:

1. Inspect the yoke axle fo~ wear in way of the axle brackets. Replace the axle if worn more than 0.010".

2. Inspect the yoke axle brackets for elongation and cracking in way of the axle holes.

Replace all damaged brackets. (See GENERAL NOTE 4-4-c)

3. Inspect the yoke safety chain and shackles for wear. Replace all chain, shackles or shackle pins that are worn to less than 90% of their original nominal diameter.

b. Ladder Connection Point:

1. Carefully inspect the _ladder-to-yoke connec tion pin for signs of wear. Replace pin if wear exceeds 0.010".

2. Inspect the ladder-to-yoke connection pin bracket for elongation or cracking in way of the pin holes. Inspect the bracket attachment welds for srgns of cracking. (See GENERAL NOTES 4-4-b and 4-4-c).

4-51 LOWER PLATFORM ASSEMBLY-

a. carefully inspect the Lower Platform axle pins and their penetrations. Replace the axle if it is worn more than 0.010" in way of.the penetra tion, or if it is bent sufficiently to prevent free movement of the platform about the axle pins.

4-8

T9623-AC-MMC-010

b. Inspect the axle pin penetration for cracks or elongation. Notify Rampmaster, Inc. if any damage is discovered in this area. Repairs in this area should not be attempted without prior approval of Rampmaster, Inc. or its authorized representative.

c. Inspect the Lower Platform adjusting pads on the platform and the ladder. The adjustment holes should properly align for all permissible angles. Inspect the holes for elongation and cracking. Notify Rampmaster, Inc. if any damage is discovered in this area. Repairs in this area should not be attempted without prior approval of Rampmaster, Inc. or its authorized representative.

d. Inspect,±he adjusting pad clevis pins for straightness'and cracks. Replace all cracked or bent clevis pins. (See GENERAL NOTE 4-4-a).

e. Replace all broken clevis pin lanyards and safety clips. (See GENERAL NOTE 4-4-a).

4-57 PENDANTS AND BRIDLES. All three (3) Chain Pendants are comprised of 3/4" diameter galvanized steel chain, shackles and connecting links.

Never paint the Chain Pendants.

a. The Pendants should be visually inspected before every use for worn links and loose shackles. Loose shackles should be ti_ghtened immediately. Links worn more·than 20% of their original nominal diameter should be replaced.

Missing links may be used to replace worn links.

4-9

Never~ more than~ ill mi.ssing link per Pendant.

b. Chain Pendants should be stored out of the weather in a clean, dry place.

4-62 WIRE ROPE PENDANTS AND SLINGS. Wire Rope Pendants

(3) and Slings (1) are comprised of galvanized preformed steel wire rope, thimbles and weldless rings.

Never paint Wire Rope Pendants or Slings.

a. Wire rope should be carefully coiled when stored, observing the rope lay to avoid kinks.

b. A quality wire rope lubricant should be applied every month if the rope was used during the preceding month.

c. Prior to each use, inspect wire rope for kinks, broken strands, possible acid damage and generally worn areas. Wire rope should be replaced when the outside wires are worn down to one-half (1/2) of their original diameter, or when·it is apparent from broken strands or other abnormal indications that the wire has been subjected to excessive strains or a sharp bend resulting in a pronounced kink.

4-10

. i

d. Inspect all thimbles and weldless rings for wear and replace any that are worn to 80% of their original nominal diameter or thickness.

e. Inspect all lashings and replace any that are missing or torn prior to using· the Pendant.

f. Replace all shackle screw pins if their threads are damaged.

4-70 SPREADER BAR

a. The Spreader Bar should be inspected prior to each use. Look for signs nf excessive corrosion over its entire surface. Replace the unit if corrosion exceeds 20% of its original nominal thickness over half of its surface area.

b. Inspect the pendant attacl:iment points for cracks or elongation. Refer to GENERAL NOTE 4-4-c for replacement guidelines.

c. Inspect the pendant shackle pins for tightness and wear. Refer to GENERAL NOTE 4-4-a for replacement guidelines.

Never~ s·bent Spreader Bar.

4-75 LUBRICATION

Lubrication of the.ladder and its various components is to be accomplished in accordance with the Lubrication Cha.rt. (_S~e Ta.bl~ 3 J •

4-11

LUBRICATION CHART

>-'l

<; PREQUEHC! > \0

TBERH DESCRIPTION . IHSPl!CTIOH HO. OP EVERY USE OR QUARTERLY SEMI-AHlftJALLY ·" ANNUALLY"'

ITEM HO. TYPE LOCATIONS MONTHLY I

I ~ ... .., () I

0 ,_.

1 MOTOR l 2 X

2. COUPLIHG 2 1 X

J GEAll REDUCER 3 1 X s PILLOW BLOCK

BBARIHG 4 1 X

4-77 INSPECTION TYPES

h MOTOR

a. Relubrication Interval

(1) Since the Lifting Winch motor is in -"seasonal" service, the.suggested re lubrication interval is one (ll year.

No lubrication is needed before start !:!E.· The bearings have been lubricated at the factory.

b. Lubricant Type

(ll A high quality, medium consistency Poly urea type ball.bearing grease is to be used. (Shell Dolium R or equal).

c. Lubrication Procedure

(ll If motor is equipped with an Alemite fitting, clean the tip of the fitting and apply grease gun. Use 2 or 3 strokes ..

If motor has a drain plug, remove plug and operate motor for 20 minutes before replacing drain plug •

4-13

Keep grease clean. Lubricate motor at a stand still. Do not mix petroleum grease and-silicone grease in motor bearings.

£.:.. GEAR COUPLING

a. Relubrication Interval

(1) The sealed couplings should have their lubricant flushed out and replaced after the initial break-in period of approx imately 40 hours of operation.

No lubrication is needed before start !:!P.· The couplings have been lubricated at the factory.

· b. Lubricant Type

(ll A high quality, general purpose grease equal to one of the following m~y be used:

(a) Atlantic Richfield Premier H 1

(b) CITGO H-2

( c) Mobilgrease No. 3,

(d) Shell Alvania EP 1

4-14

c. Lubrication Procedure

(ll Refer to the Repair Section of this manual for instructions on disassembly and inspec tion of the coupling.

(2) Upon reassembly, remove both lub~ plugs and . fill the coupling with 0.25 ounces of any recommended lubricant described above.

CAUTION

Do not overfill the coupling.

(3) Replace the two (2) lube plugs.

3. GEAR REDUCER

a. Relubrication Interval

(1) The lubricant in the Gear Reducer should be drained and replaced af·ter the first 250 hours of operation. Thereafter, the lubricant should be changed every six ill months, as shown in Table 3.

b. Lubricant Type

(1) Any of the following lubricants may be used in accordance with the ambient temperature ranges indicated.

4-15

(a) -30 to 15 degrees F:

CITGO A/W Hydr. Oil #32

Fiske Lubriplate APG-75

Gulf SL-460 E.P.

Keystone KS½-365

Mobil ATF-220

Shell Donax TD

Sun Sunvis 921

Texaco Meropa 68

Chevron· GST Oil 32

(bl 16 to 50 degrees[:

CITGO EP Comp. ,68

. Fiske Lubriplate APG 80

Gulf EP Lubricant HD 68

Keystone KLC-643

Mobilgear 626

Shell Omala 68

4-16

T9623-AC-MMC-010

Sun Sunep 1050

Texaco Meropa 68

Chevron GST Oil 68

For applications that involve severe ambient temperature extremes or seasonal requirements, use Mobil SHC 626.

c. Lubrication Procedure

(ll Drain the unit, using the drain plug provided.·

(2) Thoroughly flush the unit with a light flushing oil.

(3) Refill the unit with an appropriate lubricant from the list above.

_CAUTION · I

Do not overfill the Gear.Reducer.

4-17

WARNING

This unit may not be lubricated from the factorv.

Before start :!:!E check fluid level and fill as necessary.

EJ

To prevent loss of oil during shipment, the Gear Reducer unit is shipped with~ brass pin in the vent hole in the filler and~ pJ:!!g. Be sure that this pin is removed and discarded prior to initial operation of the_ unit.

.!.:_ PILLOW BLOCK BEARING

a. Relubrication Interval

(1) The bearing unit is prelubricated at the factory and should be relubricated at monthly intervals or at each use of the accommodation ladder.

b. Lubricant Type

(1) The bearing unit is prelubricated with a lithium base grease. Relubrication should be with a high quality lithium base ball bearing grease or with a grease that is suitable for ball bearings and that is compatible with a lithium base grease.

4-18 f

T9623-AC-MMC-010

c. Lubrication Procedure

(ll Grease should be added slowly while the shaft is rotating until a slight bead forms at the seals.

4-19

FR4B

WL

T9623-AC-MMC-:-010

FR47

.B.!11. .

STIii). SICE SHOWN

ELSY•TION

STBO. LADDER SHOWN

POR.T LADDER. SIMILAR

FIG. 2

4-20

FR .... ---r11-.. s- £ SHIP

I

REFERENCE KEY: • PARAGRAPH 4-77 {I) .

0 PARAGRAPH 4-77 (2)

6_ PARAGRAPH 4-77 l3)

D PABAGRAPH 4·77 (4) * PARAGRAPH 4 77 (2)

0 HIGH QUALITY

LITHIUM GREASE

1'9623-Ac-MMC-010

5-1 TROUBLESHOOTING

The following step-by-step procequres are to be used to logically isolate and correct problems which may occur with the Rampmaster Model AAL-2.0-41.3-X-P Accommodation Ladder and its associated equipment.

5-2 GENERAL TROUBLESHOOTING - THERN 4D3 POWER WINCH

Disconnect the unit from the primary power supply (preferably !2Y removing the circuit breaker) before attempting any inspection or repair.

PROBLEM LOOK FOR AND CORRECT

Motor will not run.

Failure in Power Supply:

1. Check primary power supply from source to unit.

2. Circuit Breaker tripped - Reset.

3. Motor Thermal Protection tripped - Reset.

4. Motor Burnt out - Replace •

5. Motor Controller contacts seized - Replace .

5-1

PROBLEM

Motor runs, but drum will not turn.

Motor tries to turn, but cannot.

T9623-AC-MMC-010

LOOK FOR AND CORRECT

Loose or broken drive compo nent - Check the following areas:

1. Motor-to-Reducer coupling.

2. Gear Reducer.

3. Reducer-to-wfnch drum:

Key sheared or set screws loose.

1. Unit severely overheated - Allow to_cool.

2. Broken gear - Inspect unit and repair or replace as required.

3. Electric Brake inoper ative - Rep_air or replace.

4. Rotary Limit Switch set incorrectly - Adjust. ·

5. Elec~ric Brake solenoid burnt out - Replace.

5-2

C

PROBLEM

Motor overheats.

Unusual Sounds.

T9623·AC-MMC-010

LOOK FOR AND CORRECT

1. Motor operated too long at capacity - Allow to cool.

2. No lubricant - Inspect affected component for damage. Fill with approved lubricant.

3. Wrong lubricant - Drain lubricant. Inspect affected component for damage. Refill with correct approved lubricant.

4. Improper alignment - Adjust.

1. Intermittent grinding or light, rapid "thumping" sounds:

5-3

a. Metal particles abraded from gears and suspended in lubricant - Inspect gears and repair.

Refill with clean lubri cant.

b. Improper clearances in motor-to-gear-box coup ling. Inspect and adjust or replace.

c. Damaged Bearing Replace.

PROBLEM

Unusual Sounds (Cont'd).

Lubricant Leaks.

T9623-AC-MMC-010

LOOK FOR AND CORRECT

d. Improper alignment - Adjust.

2. High-pitched squeak:

a. Lack of lubricant - Inspect affected compo nent for damage. Add recommended lubricant to proper level.

1. Bearing worn out - Replace ·bearing and seal.

2. Damaged.Seal - Replace Seal.

3. Loose Drain Plug Drain Plug.

Tighten

4. Plugged Vent - Clean Vent •

. 5-4

. T9623·AC-MMC-010

6-1 CORRECTIVE MAINTENANCE

Corrective Maintenance procedures for the Rampmaster accommodation ladder are limited. Maintenance for the few components that can be serviced are given below. Chapter~ Troubleshooting should be referenced before any type of maintenance is begun. Any adjustments or repairs are to be referred to Rampmaster, Inc., or its authorized representative.

The Accommodation Ladder is not to be modified or altered in any way without written consent from Rampmaster, Inc.

6-3 LIFTING WINCH (WINCH COMPONENTS ONLY). When inspection shows that parts or assemblies have-become worn, cracked, deformed, misaligned, or severely corroded, i-t is recommended that these parts and assemblies be replaced rather than repaired. Repair to various parts by straightening, welding or substitution offers no assurance of satisfactory or safe performance. Do not substitute parts of other manufacture.

If for any reason it is necessary to disassemble the power winch, mark the mating parts with a center punch or other permanent marking device so that these parts maintain the same relationship to one another when reassembled.

· 6-4 WINCH MOTOR BRAKE (Refer to Appendix A). The winch motor brake has only one part that can be repaired (replaced). This• is the friction disc. If you must replace the friction disc, you must first remove the brake housing (Part A, Refer to Appe~dix A). Then remove the Solenoid Assembly and the Stationary Disc (Part C). Now you will see the Friction Disc mounted on the Hub (Part E). Slide the disc off of the hub and replace with a new disc. Reassembly is the reverse of disassembly.

6-5 WINCH MOTOR GEAR REDUCER. Maintenance to the Gear.Reducer is limited to the-lubrication arid cooling of the unit. If a speed reducer is overfilled with oil, the energy used in churning the excessive oil can result in overheating. If this occurs, shut down .. the drive., remove _the oil level plug and allow to drain until oil ceases to drain from the level hole, • reinstall the level plug, and restart the drive. If the speed reducer is underfilled; the resultant friction can cause overheating. If this occurs, fill the speed reducer to the oil level plug hole.

6-6 MOTOR/ REDUCER COUPLING. - If the coupling between the motg_r and the gear reducer fails, it must be replaced with a new coupling: Firs·t-; ai-sconn·ect the main power supply to the winch

6-1 assembly. Free the snap rings and seals from the coupling sleeve. Slide the sleeve across the hub until the gear teeth

· are exposed. Loosen the mounting bolts for the motor so that the coupling may be freed from the motor and reducer shafts.

You are now ready to install the new coupling.

Place one new snap ring and one new seal (in this order) over each shaft end. Insert keys in shafts and mount hubs on shaft with short end of hubs flush with shaft end. Use plastic oil proof sealing compound to prevent leakage of lubricant around keys. Place sleeve over one of the hubs and engage gear teeth.

Slide sleeve across hub as far as possible toward equipment housing. This will expose the shorter end of the hub for aligning. Mount units to be connected in place and set gap, (gap is .125 or 1/8 inch). Check gap at quarter points (90 degrees apart). Align coupling using a straight edge across hub diameters. Check at quarter points· ( 90 degrees apart). Apply a small amount ·of grease on seals and hubs so seals will. slide easily over hub surface. Smear grease in and around gear teeth.

Slide sleeve across hub until gear teeth in both hubs are completely engaged. Install seals in sleeves being sure they are seated properly. Check that seals are not crimped or bent over. Install snaprings in place, being sure they are fully seated in grooves. This is very important. Remove both lube plugs and fill coupling with the required amount of lubricant.

For a list of recommended lubricants see Paragraph 4-77-2 .•

6-7 WINCH MOTOR. If the motor becomes inoperable.due to armature damage or other cause requiring rewinding of the wound stator assembly, the motor should be replaced with a 1 1/2 liP NEMA Frame 145T motor as specified on page 9-4 of the Appendix.

6-8 TILTING WINCH. The Beebe Brothers Model BM-3B 1-ton marine duty hand winch·has two (2) bronze bearings which are oil impregnated and are integral with the winch side frames.

The side frames are easily replaceable if it becomes necessary renew the bearings. The only other required maintenance would be the replacement, as needed, of the· 3/8" wire rope on the winch drum.

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. T9623·AC-MMC-010

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